Roughen, Expand, Simplify

Words to live by, possibly even outside the context of producing a distressed look in Illustrator.

(and the infectious “snap to pixel grid” setting needs to die in a fire)

[Update: Wow, they really broke the actions support in CS5.x; simple operations do not work in the standard “accelerated” mode, and you can’t just tell the damn thing to always use step-by-step mode]